EP1430987B1 - Micro-usinage par plasma induit par laser - Google Patents

Micro-usinage par plasma induit par laser Download PDF

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Publication number
EP1430987B1
EP1430987B1 EP03026596A EP03026596A EP1430987B1 EP 1430987 B1 EP1430987 B1 EP 1430987B1 EP 03026596 A EP03026596 A EP 03026596A EP 03026596 A EP03026596 A EP 03026596A EP 1430987 B1 EP1430987 B1 EP 1430987B1
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EP
European Patent Office
Prior art keywords
laser
target material
laser pulses
fuel injector
plasma
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP03026596A
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German (de)
English (en)
Other versions
EP1430987A1 (fr
Inventor
Cale E. Groen
Justin Lee Koch
William E. White
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Caterpillar Inc
Original Assignee
Caterpillar Inc
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Filing date
Publication date
Application filed by Caterpillar Inc filed Critical Caterpillar Inc
Publication of EP1430987A1 publication Critical patent/EP1430987A1/fr
Application granted granted Critical
Publication of EP1430987B1 publication Critical patent/EP1430987B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
    • F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
    • F02M61/168—Assembling; Disassembling; Manufacturing; Adjusting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/064—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/064—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
    • B23K26/0648—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms comprising lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/0665—Shaping the laser beam, e.g. by masks or multi-focusing by beam condensation on the workpiece, e.g. for focusing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/12—Working by laser beam, e.g. welding, cutting or boring in a special atmosphere, e.g. in an enclosure
    • B23K26/123—Working by laser beam, e.g. welding, cutting or boring in a special atmosphere, e.g. in an enclosure in an atmosphere of particular gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/18—Working by laser beam, e.g. welding, cutting or boring using absorbing layers on the workpiece, e.g. for marking or protecting purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/361—Removing material for deburring or mechanical trimming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B23K26/382—Removing material by boring or cutting by boring
    • B23K26/389—Removing material by boring or cutting by boring of fluid openings, e.g. nozzles, jets
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F4/00—Processes for removing metallic material from surfaces, not provided for in group C23F1/00 or C23F3/00

Definitions

  • the present invention relates to a method for laser ablation according to the preamble of claim 1 and to a system according to the preamble of claim 9 and, more particularly, to apparatus and processes for micromachining by laser ablation.
  • Lasers are used in a variety of machining applications.
  • continuous wave (CW) and long pulse width lasers have been used to cut, drill, surface modify, and mark target materials.
  • Energy from an impinging laser beam or pulse typically heats a target material from a solid phase through a liquid phase to a vapor phase causing expansion and expulsion of target material.
  • ultrashort pulse width lasers such as, for example, pulses generated by femtosecond and picosecond lasers. Because ultrashort pulse width lasers deposit energy into a target material in a very short time interval, the distance over which the heat due to the laser is dispersed is less than the absorption length of the laser. Thus, material is removed before energy loss due to thermal diffusion can occur.
  • U.S. Patent No. 5,656,186 (“the '186 patent”), reissued as U.S. RE 37,585 , discloses a method for ablating a feature smaller than the laser spot size using pulse widths less than one nanosecond and pulse energies on the order of 1 micro joule ( ⁇ J).
  • the '186 patent discloses plotting the relationship of the fluence threshold at which breakdown occurs versus the laser beam pulse width to determine a transition point at which the ablation threshold is highly dependent on pulse width. According to the '186 patent, when operating near this transition point a bulk of the pulse energy ionizes the target material to cause ablation. Because the bulk of the pulse energy ionizes the target material, micromachining at the fluence levels disclosed in the '186 patent may result in unacceptable precision and quality of the laser processed material.
  • US-A-6,303,901 discloses a method according to the preamble of claim 1 for penetrating a workpiece using an ultrashort pulse laser beam without causing damage to subsequent surfaces facing the laser.
  • US-A-6,303,901 also discloses a system according to the preamble of claim 9.
  • pulses from an ultra short pulse laser remove about 10 nm to 1000 nm of material per pulse. This occurs when the illumination fluence is near or below approximately 500-1000 milli-joules/cm 2 at the work piece.
  • the injector may be trepanned and a diagnostic used to lower the laser illumination fluence to this level either as soon as the frontal piece is penetrated or just slightly before the frontal piece is penetrated.
  • a plasma source is attached to the fuel injector and initiated by common methods such as microwave energy.
  • the sack void is filled with a solid.
  • a high viscosity liquid is placed within the sack.
  • a method for forming an orifice in a fuel injector nozzle tip includes providing the fuel injector nozzle tip in an ambient atmosphere.
  • a plurality of laser pulses are generated, each of the plurality of laser pulses having a pulse width of 1 ps or less and a fluence of 10-500 J/cm2.
  • the plurality of laser pulses are directed to trepan the fuel injector nozzle tip.
  • a gas is provided such that the plurality of laser pulses trepanning the target material interact with the gas to form a plasma.
  • the orifice is then formed by removing a portion of the fuel injector nozzle tip by interaction of the plasma with a surface of the fuel injector nozzle tip.
  • a system for micromachining includes a laser system to generate one or more laser pulses, each of the laser pulses has a pulse width of 1 ps or less and a pulse energy of 50 ⁇ J or more, and optical components to direct the one or more laser pulses towards a target material in an ambient atmosphere.
  • the system further includes at least one lens to focus the one or more laser pulses to a minimum spot size at or below a surface of the target material.
  • the system also includes a source of gas directed towards the surface of the target material such that the one or more laser pulses interact with the gas to form a plasma that removes a portion of the target material.
  • FIG. 1 depicts an exemplary system 100 for laser ablation.
  • a laser system 11 can be any chirped pulse amplified laser system capable of generating pulses having pulse widths of 1 picosecond (ps) or less, such as, for example, femtosecond or picosecond laser systems using a Ti:Sapphire oscillator.
  • Other examples of chirped pulse amplified laser systems include those using Nd:Glass, Yb:Glass, or hybrid oscillators.
  • the generated pulses are directed along a path 12 towards a target material 13 by various optical components.
  • the optical components along optical path 12 may include, for example, a mirror 14, a shutter 15, a 1 ⁇ 2 wave plate 16, a beam splitter 17, a 1 ⁇ 4 wave plate 18, periscope mirrors 19, and a lens 20.
  • a single shot autocorrelator 25 positioned in path 12 may also optionally be used to measure the pulse width.
  • Gas flow equipment 26 provides gas to a location near the surface of target material 13 upon which the laser pulses are focused.
  • Gas flow equipment 26 may, for example, provide a concentric gas along the axis of the laser pulse path immediately prior to impingement of the target material.
  • the gas can be, for example, air, helium, or argon having a flow rate of about 1 to 10 cubic feet per hour.
  • target material 13 can be an inorganic material, such as, for example, a metal.
  • Target material 13 can be in an ambient atmosphere, such as, for example, room temperature and pressure.
  • Laser system 11 can be a femtosecond laser including a Ti:Sapphire oscillator operating at 1 KHz or more. Laser system 11 generates one or more pulses, each pulse having a laser energy of about 1/10 to 50 watts, and pulse width of about 1 ps or less.
  • Optical components direct the laser pulse or pulses along path 12.
  • Lens 20 can be, for example, a 100 mm lens that focuses the pulse to a minimum spot size at or below the surface of target material 13.
  • the minimum spot size can be about 10 to 50 microns and a fluence can be about 10 to 500 J/cm 2 .
  • the laser pulse or pulses induce the gas at the surface of target material 13 to form a plasma 30. Plasma 30 then interacts with target material 13 to remove a portion of the target material.
  • laser pulses are used to generate a plasma to micromachine a desired structure from target material 13.
  • Figure 2 depicts a system 200 including similarly numbered laser system, optical components, and gas flow equipment as that depicted in Figure 1 .
  • Laser system 200 further includes an apparatus such as trepan head 225 to direct the pulses to impinge target material 13 in a predetermined pattern represented by beam paths 212 and 221. Trepanning, for example, by moving the pulses in a circular path represented by line 212 and dotted line 221 can produce a hole having a greater diameter than that produced by fixed or stationary pulses.
  • a circular hole is one example of a structure that can be produced by contour cutting and that other types of holes and structures can also be produced.
  • Trepan head 225 includes a first optical wedge 226, a second optical wedge 227, and a 1 ⁇ 2 wave plate 228. Both optical wedges 226 and 227 may be rotated in the same direction at about, for example, 20 Hz, to determine the diameter of the circular pulse path represented by line 212 and dotted line 221. Control of this ratio and, thus, the diameter of the beam path is typically automated by, for example, a servo-motor and computer.
  • target material 13 can be micromachined by moving target material in a predetermined pattern.
  • a motion system 260 having, for example, 5-axis motion can move target material 13 in a predetermined pattern such that the laser pulses interact with the gas to form a plasma that micromachines a desired feature.
  • FIG. 3 diagrammatically illustrates one particular application of the disclosed system to manufacture a fuel injector nozzle tip. This exemplary embodiment will be discussed in the following section.
  • An example of laser induced plasma micromachining according to the invention is the micromachining of an orifice in a fuel injector nozzle tip.
  • Fuel injector nozzle tips can be made from a variety of alloy steels including, for example, AISI 52100.
  • the thickness of the nozzle tip is about 500 ⁇ m to 2 mm and the orifice is about 25 to 500 ⁇ m in diameter.
  • laser system 11 operates at about 1 KHz providing pulses with energies of about 100 to 400 ⁇ J. Pulses are directed along path 12 by mirror 14, shutter 15, 1 ⁇ 2 wave plate 16, beam splitter 17, 1 ⁇ 4 wave plate 18, periscope mirrors 19, and 100 mm lens 20.
  • Concentric gas can be provided by gas flow equipment 26 to a location adjacent the surface of the fuel injector nozzle tip upon which the laser pulses are focused.
  • Gas flow of air, argon, or helium can be provided at about 1 to 10 cubic feet per hour.
  • Trepan head 225 operates the wedges at about 20 Hz to direct the laser pulses to trepan the fuel injector tip to form the orifice in the nozzle.
  • lens 20 focuses the pulses to a minimum spot size of about 10 to 50 ⁇ m at or below a surface 360 of fuel injector nozzle 350.
  • the laser pulses, trepanning a circular path represented by line 212 and dotted line 221, interact with the gas at surface 360 of nozzle tip 350 to form plasma 30.
  • Plasma 30 then removes a portion of material from surface 360 to form the orifice as the laser pulses trepan surface 360.
  • fuel injector nozzle orifices having a diameter of 25 to 500 ⁇ m require about 10 to 100 joules/hole.
  • the disclosed laser ablation system and method have wide application in any industry that requires precision machining of small structures. Although the methods and systems can be utilized to ablate organic and inorganic materials, the present invention is particularly applicable to laser induced plasma micromachining of metals. It is known that the disclosed system and method provide improved precision and quality in the laser micromachining of orifices for fuel injector tips. This provides improved performance in the finished product and lessens manufacturing costs.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Mechanical Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Laser Beam Processing (AREA)

Claims (10)

  1. Procédé d'ablation par laser comprenant les étapes suivantes :
    fourniture d'un matériau cible (13, 360) dans une atmosphère ambiante ;
    production d'une ou plusieurs impulsions laser, chacune des impulsions laser ayant une largeur d'impulsion d'une picoseconde (ps) ou moins, et une énergie d'impulsion de 50 microjoules (µJ) ou plus ;
    orientation desdites une ou plusieurs impulsions laser vers le matériau cible ;
    fourniture d'un gaz de sorte que lesdites une ou plusieurs impulsions laser interagissent avec le gaz pour former un plasma (30) ; et caractérisé par
    le retrait d'une partie du matériau cible (13, 360) par interaction du plasma (30) avec le matériau cible.
  2. Procédé selon la revendication 1, dans lequel le gaz est choisi parmi l'air, l'hélium ou l'argon.
  3. Procédé selon la revendication 1, dans lequel la largeur d'impulsion est comprise entre 100 et 1000 femto-secondes.
  4. Procédé selon la revendication 1, dans lequel chaque impulsion laser fournit une fluence d'environ 10 à 500 J/cm2 .
  5. Procédé selon la revendication 4 pour former un orifice dans l'embout d'une buse d'injecteur de carburant (350), dans lequel ledit matériau cible est un embout de buse d'injecteur de carburant (350) ;
    dans lequel ladite étape d'orientation comprend l'orientation de la pluralité d'impulsions laser pour trépaner l'embout de buse d'injecteur de carburant (350) ; et
    dans lequel l'étape de retrait comprend la formation de l'orifice en retirant une partie de l'embout de buse d'injecteur de carburant par l'interaction du plasma avec une surface (360) de l'embout de buse d'injecteur de carburant (350).
  6. Procédé selon la revendication 5, dans lequel la buse d'injecteur de carburant comprend un alliage d'acier.
  7. Procédé selon la revendication 5, dans lequel l'orifice est circulaire et a un diamètre de 25 à 500 µm.
  8. Procédé selon la revendication 5, dans lequel l'énergie du laser pour former l'orifice est comprise entre 10 et 100 joules.
  9. Système (100, 200) destiné à un micro-usinage comprenant :
    un système laser (11) produisant une ou plusieurs impulsions laser, chaque impulsion laser ayant une largeur d'impulsion de 1 ps ou moins et une énergie d'impulsion de 50 µJ ou plus ;
    des composants optiques (14, 15, 16, 17, 18, 19) pour orienter lesdites une ou plusieurs impulsions laser vers un matériau cible (13) ;
    au moins un objectif (20) pour focaliser lesdites une ou plusieurs impulsions laser vers un point de dimensions minimum au niveau ou en dessous d'une surface du matériau cible (13), caractérisé en ce qu'il comprend en outre :
    une source de gaz dirigée vers la surface du matériau cible de sorte que lesdites une ou plusieurs impulsions laser interagissent avec le gaz pour former un plasma (30), le plasma (30) étant capable de retirer une partie d'un matériau cible.
  10. Système selon la revendication 9, comprenant en outre des composants optiques (225, 226, 227, 228) pour orienter lesdites une ou plusieurs impulsions laser pour trépaner un matériau cible.
EP03026596A 2002-12-20 2003-11-19 Micro-usinage par plasma induit par laser Expired - Lifetime EP1430987B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/324,076 US6852946B2 (en) 2002-12-20 2002-12-20 Laser-induced plasma micromachining
US324076 2002-12-20

Publications (2)

Publication Number Publication Date
EP1430987A1 EP1430987A1 (fr) 2004-06-23
EP1430987B1 true EP1430987B1 (fr) 2008-10-08

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US6852946B2 (en) 2005-02-08
EP1430987A1 (fr) 2004-06-23
US20040118823A1 (en) 2004-06-24
DE60323929D1 (de) 2008-11-20

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